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Compressed Air

SPRINT
005 - 047

INT SPR045

INT SPR020

Operating instructions Screw compressor SPRINT

Ident. No.: 114 412 74/00

BA 121/GB (03/95) 1

1. Foreword

1.1 Notes on the compressor


Mannesmann Demag screw compressors are the result of many years of research and development. These prerequisites combined with high quality standards guarantee the manufacture of screw compressors providing a long service life, high reliability and cost-effective operation. It stands to reason that all requirements concerning environmental protection are met.

In addition, * relevant accident prevention regulations, * generally recognized safety regulations and * national regulations have to be observed. The machine/unit must only be used in technically perfect condition and in accordance with its intended use and the instructions set out in the operating manual, and only by safety-conscious persons who are fully aware of the risks involved in operating the machine/unit! Any functional defects, especially those affecting the safety, have to be rectified immediately (or rectified by others)! The machine/unit is designed exclusively for the generation of compressed air to power air-driven devices. Using the machine/unit for purposes other than those mentioned above is considered contrary to its intended use. The manufacturer/supplier cannot be held responsible for damage resulting from such use. The risk of such misuse lies solely with the user. Operating the machine within the limits of its intended use also involves observing the instructions set out in the operating manual and complying with the inspection and maintenance directives.

Certificate of conformity
The compressor and its accessories as supplied by Mannesmann Demag conform to the basic safety and health requirements included in the EC Machinery Directive 89/392/EWG, version 93/44/EWG. The compliance with these directives is confirmed by the "CE mark" (fig. 1).

1.3 Maintenance
Carefully performed maintenance is imperative, this ensures that your screw compressor can meet all the requirements placed upon it. It is therefore imperative to adhere to the specified maintenance intervals and to carry out the maintenance work with particular care, especially when the unit is utilized under harsh operating conditions.

Fig. 1

1.2 Intended use


The machine/unit has been constructed in accordance with state-of-the-art technology and the recognized safety regulations. Nevertheless, its use may constitute a risk to life and limb of the user or third persons or cause damage to the machine or to other material property, if * * * * it is not used as intended, it is operated by unqualified personnel, it is improperly modified or changed, the safety regulations are not observed.

Servicing
Please contact your authorized Mannesmann Demag dealer in the case of malfunctions or when spare parts are required. In the case of damage, our fully trained personnel will ensure that a quick and proper repair is carried out using original Mannesmann Demag spare parts. Original Mannesmann Demag spare parts are manufactured utilizing state-of-the-art technology, thus guaranteeing the further reliable operation of the unit.

In case of queries
Please enter the data on the nameplate of your compressor into the nameplate shown below (fig. 2). In the case of queries or spare parts orders, please refer to the compressor type indicated on the nameplate, the identification no. and the year of construction. With this information at hand it can be guaranteed that you will receive the right information or required spare parts.

Therefore, any person entrusted with the operation, maintenance or repair of the machine must read and follow the safety regulations. If required, this has to be acknowledged by signature.

1. Foreword

Guarantee
Operate this compressor only if you have an exact knowledge of the machine taking into respect these instructions. Mannesmann Demag Drucklufttechnik cannot be held responsible for the safe operation of the machine/unit if it is used in a manner, which does not correspond to the intended use, or for other applications, which are not mentioned in these instructions. Warranty claims will not be accepted in the case of * * * * Operating errors Incorrect maintenance Wrong auxiliary materials Use of spare parts other than Mannesmann Demag original spare parts * Modifications and changes to the installation The warranty and liability conditions of the general terms and conditions of Mannesmann Demag Drucklufttechnik will not be extended by the notes above. Fig. 2 Any unauthorized change to the compressor unit/station, or the installation of components not accepted by the manufacturer (e.g. fine separator) will result in the withdrawal of the CE mark. As a consequence, any liability and warranty claims will not be accepted by the manufacturer.

1.4 Notes General


These operating instructions are intended to familiarize the user with the machine/unit and its intended use. The instructions contain important notes on how to operate the compressor safely, properly and cost-effectively. Observing these instructions helps to avoid risks, to reduce repair costs and downtimes and to increase the reliability and service life of the machine/unit. The operating instructions have to be supplemented by the respective national rules and regulations regarding the prevention of accidents and environmental protection. They must always be available at the location of the machine/unit. The operating instructions must be read and followed by any person carrying out work in connection with the machine/unit, e.g. operation, including setting up, trouble-shooting in the operation cycles, disposal of production waste, care, service, and disposal of waste fuels and consumables, upkeep (maintenance, inspection, repair), transport. Besides the operating instructions and the binding regulations for the prevention of accidents, which are valid in the country and place of operation of the machine/unit, the generally recognized technical regulations for safe and proper working have also to be observed.

Safety regulations

Danger.
The safety regulations in chapter 3 of the operating instructions have to be strictly observed.

Technical changes
In the course of technical development we reserve the right to modify the units without further notice.

2. Table of contents

1.

Foreword ........................................................................................................................................................... 2 1.1 1.2 1.3 1.4 Notes on the compressor .......................................................................................................................... 2 Intended use .............................................................................................................................................. 2 Maintenance .............................................................................................................................................. 2 Notes ......................................................................................................................................................... 3

2.

Table of contents .............................................................................................................................................. 4

3.

Safety regulations ............................................................................................................................................. 6 3.1 3.2 3.3 3.4 3.5 3.6 3.7 Identification of safety guidelines ............................................................................................................... 6 General safety instructions ........................................................................................................................ 6 Changes and modifications to the machine ............................................................................................... 7 Installation and normal operation .............................................................................................................. 7 Special work/maintenance ....................................................................................................................... 10 Warning of special dangers ..................................................................................................................... 12 Symbols and explanations ....................................................................................................................... 14

4.

Design and functioning .................................................................................................................................. 19 4.1 4.2 4.3 4.4 4.5 Design of the unit ..................................................................................................................................... 18 Schematic diagram .................................................................................................................................. 20 Oil circuit .................................................................................................................................................. 21 Air circuit .................................................................................................................................................. 21 Start/stop/shutdown ................................................................................................................................. 21

5.

Transport and installation .............................................................................................................................. 23 5.1 5.2 Transport ................................................................................................................................................. 23 Installation ............................................................................................................................................... 23

6.

Preparations for commissioning ................................................................................................................... 25 6.1 6.2 6.3 6.4 6.5 Cooling air volume/minimum cross-sections ........................................................................................... 25 Compressed air connection ..................................................................................................................... 25 Electrical connection ................................................................................................................................ 26 Oil level check ......................................................................................................................................... 28 Sound pressure level ............................................................................................................................... 28

7.

Commissioning ............................................................................................................................................... 29 7.1 7.2 7.3 7.4 7.5 7.6 First commissioning ................................................................................................................................. 29 Routine commissioning ........................................................................................................................... 29 Commissioning after malfunction ............................................................................................................ 30 Operating modes ..................................................................................................................................... 30 Setting of the operating pressure ............................................................................................................ 30 Monitoring ................................................................................................................................................ 31

8.

DELCOS-S Electronics ................................................................................................................................... 32 8.1 8.2 8.3 8.4 Operating elements ................................................................................................................................. 32 LED "operating pressure" (bar) ................................................................................................................ 33 LED "temperature" (C) ........................................................................................................................... 33 DELCOS-SM ........................................................................................................................................... 33

2. Table of contents

9.

Maintenance .................................................................................................................................................... 34 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.14 Maintenance recommendations .............................................................................................................. Maintenance electric motor ..................................................................................................................... Maintenance schedule ............................................................................................................................. Oil change ............................................................................................................................................... Change of the oil filter cartridge ............................................................................................................... Change of the oil fine separator cartridge ............................................................................................... Air filter change/check ............................................................................................................................. Safety valve ............................................................................................................................................. V-belts - automatic tensioning system ..................................................................................................... Connecting terminals in the switch cabinet .............................................................................................. Fittings ..................................................................................................................................................... General maintenance and cleaning ......................................................................................................... Lubricant recommendations for stationary compressors ......................................................................... 34 34 34 36 37 37 38 39 39 40 40 40 40

10.

Trouble-shooting ............................................................................................................................................ 41

3. Safety regulations

3.1 Identification of safety guidelines


Mannesmann Demag is not liable for any damage or injury resulting from the non-observance of these safety instructions or negligence of the usual care and attention required during handling, operation, maintenance or repair, even if this is not explicitly mentioned in these operating instructions. If any of the regulations contained in these instructions - especially with regard to safety - does not correspond to the local legal provisions, the stricter of both shall prevail. These safety regulations are general and valid for various types of machines and equipment. It is therefore possible that some references do not apply to the unit(s) described in these instructions.

3.2 General safety instructions Organizational measures


The operating instructions must always be at hand at the place of operation of the machine/unit (in the tool compartment or box provided for such a purpose) ! In addition to the operating instructions, all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection must be adhered to and passed on to others ! These compulsory regulations may also deal with the handling of hazardous materials or the issuing/wearing of personal protective equipment, or traffic regulations. Instructions, including supervisory responsibility and duty of notification for taking into account in-plant factors, for example regarding work organization, sequences of operations, personnel assigned to certain tasks, are to be added to the operating manual. The personnel entrusted with working on the machine must have read the operating instructions and in particular the chapter on safety regulations before starting work. Reading the instructions after work has begun is too late. This applies especially to persons working only occasionally on the machine, e.g. for setting up or maintenance. Check on a regular basis that the personnel are carrying out the work in compliance with the operating instructions and that they are paying attention to the safety requirements ! For safety reasons, long hair must be tied back or otherwise secured, garments must be close-fitting and no jewellery - such as rings - may be worn. Injury may result from being caught up in the machinery or from rings catching on moving parts ! As necessary or as required by regulations, personal protective equipment should be used. Observe all safety and warning notices attached to the machine/unit ! See to it that safety instructions and warnings attached to the machine are always complete and perfectly legible. In the case of safety-relevant changes to the machine/ unit or its operating behaviour, stop the machine/unit immediately and report the fault to the responsible department/person ! Spare parts have to comply with the technical requirements specified by the manufacturer. This can always be ensured by using original spare parts. Hydraulic hoses have to be changed within stipulated and periodic intervals, even if no safety-relevant faults have been detected !

Danger.
Passages marked with this sign indicate a possible danger to persons.

Important
Passages marked with this sign indicate a possible danger to machines or part of machines.

Note
Passages marked with this sign provide technical information on an optimal cost-effective use of the machine.

3. Safety regulations

Adhere to prescribed intervals or those specified in the operating instructions for routine checks and inspections ! For the execution of maintenance work, tools and workshop equipment adapted to the task on hand are absolutely indispensable. The personnel must be made familiar with the location and operation instructions of fire extinguishers ! Observe all fire-warning and fire-fighting procedures ! Limit values (pressures, time settings, etc.) have to be permanently identified !

3.3 Changes and modifications to the machine


Do not make any changes, modifications or attachments to the machine/unit, which could affect safety, without the supplier's prior permission ! Unauthorized changes to the machine are not permitted for safety reasons. Original parts were especially designed for this machine. We would like to point out that we have not released and will not release parts and special accessories which have not been supplied by us. The installation and/or use of such products can therefore affect the active and/or passive safety. The manufacturer is not liable for damage resulting from the use of non-original parts or special accessories. This applies also to the installation and setting of safety equipment and valves as well as to welding on structural parts.

Selection and qualification of personnel; basic responsibilities


Work on/with the machine/unit must be carried out by reliable personnel only. Statutory minimum age limits must be observed! Employ only trained or instructed personnel and clearly set out the individual responsibilities of the personnel for operation, set-up, maintenance and repair ! Ensure that only authorized personnel work on or with the machine ! Define the machine operator's responsibilities giving the operator the authority to refuse instructions by third persons that are contrary to safety regulations. Do not allow persons to be trained or instructed or persons taking part in a general training course to work on or with the machine/unit without being permanently supervised by an experienced person ! Work on the electrical equipment of the machine/unit must be carried out only by a skilled electrician in accordance with electrical engineering rules and regulations. Work on system elements such as hoses may only be carried out by personnel with special knowledge and experience of hydraulics !

3.4 Installation and normal operation Installation


In addition to the general technical operation in accordance with the stipulations of the local authorities, we would like to refer in particular to the following regulations. For the lifting of a compressor, a suitable lifting mechanism is to be used, which meets the local safety regulations. All loose or slewable parts must be safely fixed before the machine can be lifted. It is strictly prohibited to stay in the danger zone of a lifted load. The correct method of lifting (according to the operating instructions of the load suspension device) has to be ensured. All blind flanges, plugs, caps and bags with drying agent have to be removed prior to the installation of the pipes. Distributing pipes and pipe connections have to be of the proper size and suitable for the relevant operating pressure. The system has to be installed in such a way that it is adequately accessible and the required cooling is guaranteed. Never block the air intake. Make sure that the ingress of humidity via the intake air is kept to a minimum.

3. Safety regulations

The air intake is to be located so that no hazardous constituent (solvent vapour, etc., but also dusts and other hazardous material) can be sucked in. This applies also to flying sparks. The air intake is to be positioned so that no loose clothing of persons can be sucked in. Make sure that the pressure line from the compressor to the aftercooler or the air circuit can expand under heat and does not come into contact with inflammable material. The pressure line connected to the air outlet of the system must be fitted stress-free. If a remote control is used, the system must carry a clearly visible sign with the following note : Attention ! This installation is operated by remote control and can start up without prior warning ! As an additional safety measure, persons, who start remotely controlled systems, have to take sufficient safety precautions in order to ensure that nobody is checking the system or working on it. For this, a label with a corresponding warning notice has to be attached to the remote control equipment. Compressed air and cooling water lines have to be clearly marked in line with the local regulations. If a system comprises several compressors, handoperated isolator valves have to be installed in order to be able to shut off each machine individually. When operating pressure systems, do not rely on the effectiveness of check valves alone to isolate these systems. Safety equipment, protective covers or insulation must not be removed or modified. Any pressure reservoir, which is located outside the system, the permissible operating pressure of which is higher than the atmospheric pressure and which is fitted with two or more pressure supply lines, has to be equipped with additional safety equipment, which will automatically prevent the admissible operating pressure from rising by more than 10 %. The min. and max. temperatures of +1 C and +40 C are also valid for the intake air. Pipes and/or other parts with a surface temperature higher than 80 C have to be suitably identified and shielded against touching. Electrical connections must meet the local regulations. Power units must be connected to earth and protected from short-circuits by means of fuses.

Cold dryer
Wherever possible, the cold dryer should be installed in a place where the ambient air is as clean as possible and where the temperatures never rise above or fall below the respective limit values as indicated in the operating instructions. If required, the cooling air is to be taken from a cleaner, cooler or warmer area via an intake channel; depending on the size of the machine, an additional ventilator could turn out to be necessary. If the room temperature can fall below zero, the condensation drain system must be protected from freezing, e.g. by means of a steam heater. If it is possible that the intake temperature of the air will exceed, from time to time, the admissible maximum specified in the operating instructions, a pre-cooler with condensate drain is to be installed before the dryer. Tests or repair work on the coolant circuit may only be carried out in a well vented room. Never breath in coolant vapour; if necessary, wear a breathing mask. Always wear protective goggles and gloves. If skin comes into contact with coolants, rinse well with water. Never take off or tear up clothes but rinse them well with water until the coolant is washed off; then see a doctor.

Condensate drain
The drain hose for condensate discharge is to be connected to the drains or to a collecting reservoir, if local regulations prohibit direct discharge to the drains. In connection with this, it must be taken into account that the condensate from compressors with oil-lubricated pressure chambers can contain oil.

Normal operation
Take the necessary precautions to ensure that the machine is used only when in a safe and reliable state ! Operate the machine only when all protective equipment, emergency shut-off equipment, sound-proofing elements and extraction devices are in place and fully functional !

3. Safety regulations

Check regularly that * all means of protection are correctly fitted and fixed, * all hoses and/or pipes within the system are in good condition, firmly fixed and do not chafe, * there are no leakages (fuel, oil or coolant), * all fittings are firmly tightened, * all wires are connected correctly and are in good condition, * all safety valves and other pressure relief mechanisms are in good order and not blocked by e.g. dirt or paint, * the safety mechanisms are fully functional. If compressed air hoses are used, they must be of the proper size and suitable for the relevant operating pressure. Do not use chafed, damaged or poor-quality hoses. Only use hose couplings and fittings of the right type and the correct size. Before blowing through a hose or an air pipe ensure that the open end is positively held. A free end whips and can cause injuries. Before decoupling a hose ensure that it is pressureless. Refrain from any working method which is doubtful in terms of safety. Never play around with compressed air ! Never aim compressed air at your skin or at other persons ! Never use compressed air to clean your clothing. When using compressed air to clean equipment take the utmost care and always wear protective goggles. The compressed air generated by these compressors must never be used for breathing unless it has been conditioned for those applications in line with the "safety requirements for respiratory air. Never use the machine in an environment, where inflammable or poisonous vapour can be sucked in. Never operate the system at pressures and temperatures below or above the values indicated in the technical data sheet. The access panels, etc. have to be closed during operation. Persons who stay in an environment or rooms, in which the sound pressure is 85 dB(A) or higher, have to wear ear protectors.

Check the machine/unit at least once per shift for visible damage and faults ! Report any changes (including changes in the machines operating behaviour) to the responsible department/person immediately. If necessary, stop and lock the machine immediately ! In the case of malfunction, stop the machine/unit immediately and lock it ! Have any defects rectified immediately ! Observe the start-up and stopping procedures and the control displays according to the operating instructions. Before starting up or setting the machine in motion, ensure that nobody is at risk. Do not cut off or remove extraction or venting facilities while the machine is running.

3. Safety regulations

3.5 Special work/maintenance Carefulness


Observe the adjusting, maintenance and inspection activities and intervals set out in the operating instructions, including information on the replacement of parts and equipment. These activities may be carried out by skilled personnel only. Brief the operating personnel prior to starting special operations or maintenance work ! Appoint a person to supervise the activities ! Maintenance and repair work may only be carried out under the supervision of a person who is qualified for this work. Oil losses result in a slippery floor. Therefore, always clean the floor and the outside of the machine prior to starting the maintenance work. Checks, maintenance and repair work may only be carried out with the screw compressor being at rest and depressurized. Protective equipment to be removed for this work, has to be refitted after completion of these activities. Operation of the machine without protective equipment is not permitted. When working on a running screw compressor system, working clothes have to be close-fitting. If the machine/unit is completely shut down for maintenance and repair work, it must be secured against inadvertent restarting : * Lock the main command elements and remove the key and/or * attach a warning sign to the main switch. Always use the correct tools for maintenance and repair work. Never use inflammable solvents or carbon tetrachloride to clean parts. Take precautions against poisonous vapours from cleaning agents. In any work concerning the operation, conversion or adjustment of the machine and its safety-oriented devices or any work related to maintenance, inspection and repair, always observe the start-up and shutdown procedures set out in the operating instructions and the information on maintenance work. Ensure that the maintenance area is adequately secured. To lower the risk of accidents, individual parts and large assemblies being moved for replacement purposes should be carefully attached to lifting tackle and secured. Use only suitable and technically correct lifting gear and only utilize suspension systems with adequate lifting capacity. Never work or stand under suspended loads !

During maintenance and when carrying out repair work, cleanliness is very important. Avoid the ingress of dirt by covering parts and free openings with a clean cloth, paper or adhesive tape. After the completion of each repair, check that tooling or loose parts have not been left in the machine, drive motor or drive equipment and ensure that no cloth has been left inside these units. Be careful when the screw compressor system is in operation.

Maintenance/rectification of faults
The employer has to inform the employee of the dangers possibly arising during the repair and maintenance of the machine/unit as well as on how to avoid them; the employee has to observe all measures for safety at work. Safety equipment for the prevention or elimination of danger has to be maintained regularly and functionally checked at least once a year. Faults observed have to be immediately rectified and/or reported to the responsible person. Use only original spare parts. Only carry out maintenance and repair work when the system is not in operation and the power supply disconnected. Ensure that the power unit cannot be switched on inadvertently. Before removing or opening pressurized components, positively isolate any source of pressure and depressurize the entire system. Never weld near oil systems or carry out any other work requiring heat. Pressure reservoirs or components and pipes containing oil have to be drained completely and cleaned, for example by means of a steam jet, before beginning such work. Never weld any pressure reservoir or change it in any way. If work which produces heat, flames or sparks has to be carried out on a machine, the adjacent components have to be protected by means of non inflammable material. Before releasing the power unit for operation after maintenance or overhaul, check that the operating pressures, temperatures and time settings are correct and that the regulating and shut-down equipment function properly.

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3. Safety regulations

Examine the pressure tube and the pressure vibration dampers for carbon deposits every six months. Excessive deposits have to be removed. Motor, air filter, electrical components and regulating equipment have to protected from the ingress of humidity, e.g. when cleaning the system by means of a steam jet. Under no circumstance must the sound-proofing material be removed or modified. Never use etching solvents which could attack the materials used. If indicated or if there is any suspicion that an internal part of the machine has run hot, the machine has to be shut down. In order to avoid an increase in the operating temperature, check and clean the heat transfer surfaces (cooling fins, intermediate cooler, water cooling jackets, etc.) at regular intervals. Prepare a plan of the most favourable cleaning intervals for each machine. Avoid damage to the safety valves and other pressure reducing components. Check in particular for clogging caused by paint, oil carbon or the accumulation of dust, which could deteriorate the effectiveness of these components. Insulation or protective shielding, the temperature of which may exceed 80 C and which could be erroneously touched by the personnel, must not be removed before these parts have cooled down to room temperature. Check the accuracy of pressure and temperature indicators at regular intervals. If the admissible tolerance limits have been exceeded, these devices have to be replaced. Before removing or overhauling a compressor, a motor or another machine, ensure that all moveable parts of a mass of more than 15 kg cannot move or roll away. After completion of repair work, always verify that no tools, loose parts or cloths have been left in or on the machine, drive motor or drive equipment. Machines performing a back and forward main movement have to be cycled at least once, rotating machines have to be cycled several times in order to ensure that there are no mechanical faults in the machine or the drive member. Check the direction of rotation of the electric motors during first commissioning and after each modification of the electrical connections in order to prevent the compressor from being damaged.

The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only. The person giving the instructions must be within sight or voice contact with the operator. For carrying out overhead assembly work always use specially designed or otherwise safety-orientated ladders and working platforms. Never use machine parts as a climbing aid. Wear a safety harness when carrying out maintenance work at greater heights. Keep all steps, handles, handrails, platforms, landings and ladders free from dirt, snow and ice ! Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance or repair work ! Never use aggressive detergents ! Use lint-free cleaning rags ! Before cleaning the machine with water or steam jet (high pressure cleaner) or other cleaning agents, cover/ mask all openings which have to be protected from the ingress of water, steam or detergents for safety and/or functional reasons, in particular electric motors and switch cabinets. After cleaning, remove the covers/masking completely ! Check all hydraulic oil lines for leakage, loose fittings, abrasion and damage after cleaning. Any defect must be rectified immediately ! Always re-tighten screwed connections which have been loosened for maintenance and repair work. If the set-up, maintenance or repair require the demounting of safety equipment, this equipment has to be remounted and checked immediately after these activities. Ensure that consumables and replacement parts are disposed of in a safe and environmentally friendly manner.

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3. Safety regulations

3.6 Warning of special dangers Electric energy


Use only original fuses with the specified current rating. Switch off the machine/unit immediately if trouble occurs in the electric system. Work on the electrical system or equipment may only be carried out by a skilled electrician or by specially instructed personnel under the control and supervision of such an electrician and in line with the relevant electrical engineering rules. If regulations require, the power supply to parts of machines and plants, on which inspection, maintenance and repair work is to be carried out, must be cut off. Before starting any work, check the de-energized parts for the presence of power and ground or short-circuit them in addition to insulating adjacent live parts and elements. The electrical equipment of the machines/units is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately. Necessary work on live parts and elements must be carried out in the presence of a second person who can cut off the power supply in case of danger by operating the emergency shutdown or main power switch. Secure the working area with a red-and-white safety chain and a warning sign. Use insulated tools only. Before starting work on high-voltage assemblies and after having cut out the power supply, the feeder cable must be grounded, and components, such as capacitors, short-circuited with a grounding rod.

Hydraulics, pneumatics
Work on hydraulic equipment may only be carried out by persons with special knowledge and experience of hydraulics. Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immediately. High pressure jets of oil may cause injury and fire. Depressurize all system sections and pressure pipes (hydraulic system, compressed-air system) which are to be removed in accordance with the specific instructions for the assemblies concerned before carrying out any repair work. Hydraulic and compressed-air lines must be laid and fitted properly. Ensure that no connections are exchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements.

Noise
Sound-proofing elements on the machine/unit have to be active during operation (i.e. sound-proofing panels closed, etc.). Wear personal ear protection as prescribed. Noise, even at a low level, can cause nervousness and annoyance; over a longer period of time, our nervous system can suffer serious damage. We therefore recommend a separate machine room in order to keep the noise of the machine away from the workshop. Depending on the number of machines in a machine room, the noise can be quite loud. In accordance with the sound pressure level at manned posts, the following precautions have to be taken : * Below 70 dB(A) : No special measures * Above 70 dB(A) Persons who stay permanently in this room have to wear ear protectors * Below 85 dB(A) In the case of occasional visitors who stay in this room only for a short while, no special precautions are to be taken * Above 85 dB(A) Hazardous noise zone ! A warning sign has to be attached to each entrance indicating that everybody who enters the room - even for a short time only has to wear ear protectors.

Gas, dust, steam and smoke


Carry out welding, flame-cutting and grinding work on the machine/unit only if this has been expressly authorized, as there may be a risk of explosion and fire. Before carrying out welding, flame-cutting and grinding operations, clean the machine/unit and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion) ! Adhere to the regulations valid for the place of operation ! Observe any existing national regulations if work is to be carried out in small rooms.

12

3. Safety regulations

* Above 95 dB(A) The warning signs have to contain the recommendation that occasional visitors also have to wear ear protectors. * Above 105 dB(A) Special ear protectors, which are suitable for the noise level and the spectral composition of the noise must be available. A corresponding warning sign must be fixed to each entrance door. Take care that the noise transmission through walls and frames does not result in too high a noise level in the surrounding areas.

Oils, greases and other chemical substances


When handling oils, greases and other chemical substances, observe the safety regulations for this product ! Be careful when handling hot fuels and consumables (danger of burning or scalding) !

Rooms subject to explosion hazards

Danger.
Compressor units must never be operated in areas subject to explosion hazards! (Exception: Special units with the corresponding technical modifications)

13

3. Safety regulations

3.7 Symbols and explanations

Carefully read the operating manual before commissioning or servicing this compressor.

Never operate the machine without protective equipment fitted.

Never breath in compressed air from this system.

14

3. Safety regulations

Warning:

Never operate the unit with open doors or loose access panels.

Warning:

Hot surface

Warning:

Pressurized part or system

15

3. Safety regulations

Warning:

This system can start up by means of a remote control or automatically after a power failure.

Warning:

The system continues to run for 30 seconds after pressing the O-key.

Warning:

Danger of electric shock

16

3. Safety regulations

Lifting point

17

4. Design and functioning

4.1 Design of the unit

11

12

T RIN 0 SP 02

10

14

15 1 6

13 4.1 8 7 5

2 9

Fig. 3

1 2 3 4 4.1 5 6 7 8

Screw compressor El. motor Air filter Pressure reservoir Oil fine separator Dip stick Oil filter Oil cooler Air cooler

9 10 11 12 13 14 15

Fan V-belt Operating panel of control Switch cabinet Pressure monitor Compressed air outlet Intake regulator

18

4. Design and functioning

11

12

10

T RIN 5 SP 04

14
3 15 1 6 2 9

13 4.1

7 5 4

Fig. 4

1 2 3 4 4.1 5 6 7 8

Screw compressor El. motor Air filter Pressure reservoir Oil fine separator Dip stick Oil filter Oil cooler Air cooler

9 10 11 12 13 14 15

Fan V-belt Operating panel of control Switch cabinet Pressure monitor Compressed air outlet Intake regulator

19

4. Design and functioning

4.2 Schematic diagram

Fig 5 1. 2. 2.1 2.2 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Intake filter Intake regulator Actuating cylinder Throttle valve Electric motor Screw compressor Thermo-sensor + indicator Pressure reservoir Oil fine separator Oil drain ball valve Safety valve Switch of oil filter (maintenance)* Oil filter Oil cooler Throttle Check valve Pressure holding + check valve Air cooler Pressure monitor 18. Pressure monitor + display 20. 3/2-way solenoid valve 21. Oil temperature regulator 22. Oil level indicator 23. Switch of intake filter (maintenance)* 24. Switch of fine separator (maintenance)* S3 Pressure monitor S5 Differential pressure oil filter* S6 Differential pressure oil fine separator* S7 Differential pressure air filter* B1 Sensor mains pressure* S8 Oil injection pressure* S10 Direction of rotation B2 Sensor compression monitor* end pressure R1 Motor temperature* R2 Compressor temperature R3 Oil injection temp.* R6 After-cooler temperature* Y1 Regulating valve

* option

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4. Design and functioning

4.3 Oil circuit


The required oil is drawn from the pressure reservoir6 -, passes through the oil thermostat - 21 - (closes the by-pass line of the oil cooler - 12 - and opens the passage to the oil cooler at an oil temperature > 55 C), through the oil filter - 11 - and is fed to the screw compressor - 4 -. The oil separated in the fine separator - 7 - is fed through an oil line to the screw compressor - 4 -. The entire oil circulation is based on a natural differential pressure in the system. Considering the pressure difference of approx. 1.5 bar within the oil circuit, the oil is then injected into the compressor - 4 - with approx. 5.5 bar at a reservoir pressure of e.g. 7 bar. During idle running of the screw compressor, a residual pressure of 2.0 to 3.0 is maintained. A vacuum pressure at the inlet connection produces a sufficiently high pressures drop to ensure the required oil injection quantity.

* *

The throttle valve - 2.1 - in the intake regulator - 2 opens. The valve combination (pressure holding and check valve) - 15 - opens at a system pressure of approx. 4.5 bar. The delivery of compressed air into the consumer network starts.

Automatic operation (open/close operation)


* When the mains pressure reaches the maximum value set at pressure monitor - 17 -, the solenoid valve - 20 - de-energizes. The pilot pressure is no longer present at the actuating cylinder - 2.1 -. The compression spring in the actuating cylinder - 2.1 - of the intake regulator 2 - closes the throttle valve - 2.2 -. The control chamber of the actuating cylinder is bled into the intake channel via throttle - 13 -. The screw compressor - 4 - is running in the idle mode. The pressure reservoir - 6 - is depressurized. If the mains pressure does not fall to the minimum value set at pressure monitor - 17 - within 6 minutes, the system shuts down. If the minimum value preset at pressure monitor 17 - is reached in less than 6 minutes, the solenoid valve - 20 - is again energized. The unit changes over to load operation.

* * *

4.4 Air circuit


The intake air passes through the suction filter - 1 and the intake regulator - 2 - into the screw compressor - 4 -. During the compression process, the intake air is cooled via the injected oil, and the developed air/oil mixture flows tangentially into the pressure reservoir (oil reservoir) - 6 -. After the pre-separation and the subsequent fine separation in the oil fine separator - 7 -, the compressed air with a low oil content passes through the valve combination - 15 -, the air cooler - 16 - and the condensate separator (option) into the consumer network. The condensate separated in the condensate separator (option) is carried to the outside via a solenoid valve (option) which is to be installed by the customer and controlled by a "Kondensomat (option).

Throttling operation (optional for SPRINT II 025-047)


* The upper switching point is set to the maximum operating pressure at pressure monitor - 17 (0.3 bar higher than the setting of the proportional regulator). The standard proportional regulator can only be used for a pressure range of between 7 bar and the nominal pressure. The regulation range can be set lower by adjusting the proportional regulator accordingly. With an increasing input pressure (increasing pressure in the pressure reservoir - 6 -), the proportional regulator provides a decreasing output pressure within the regulating range (corresponds to a decreasing pilot pressure in the lower control chamber of the actuator - 2.1 -). As a result of the pressure drop in the lower control chamber, the compression spring in the upper control chamber partly closes the pressure control valve - 2.2 - and thus causes throttling of the intake flow.

* *

4.6 Start/stop/shutdown
Start of the unit * * * * The electric motor - 3 - starts up in the Y-mode. The intake regulator - 2 - is closed. The oil supply of the screw compressor - 4 - is provided by the vacuum pressure where the injection takes place. When changing over to -operation, solenoid valve - 20 - switches due to being energized. The air in the system circulates via the solenoid valve - 20 - into the actuating cylinder - 2.2 -.

* *

21

4. Design and functioning

Note
The throttling operation provides only a restricted throttling function, the task of which is to reduce the supply flow to 70 %. When this value is reached, the pressure monitor - 17 - switches the screw compressor unit over to automatic operation.

Stopping of the system


* * * After pressing the OFF-key on the operating panel, the solenoid valve - 20 - is de-energized. The pressure control valve - 2.2 - in the intake regulator - 2 - closes and the system is relieved. After approximately 30 seconds, the electric motor - 3 - shuts down.

Standstill of the system


* When the system is at rest the intake controller - 2 is closed by a compression spring in the actuating cylinder - 2.1 -. The solenoid valve - 20 - is de-energized. The pressure reservoir - 6 - is bled via the solenoid valve - 20 - into the intake channel.

* *

22

5. Transport and installation

5.1 Transport

Weights (with electric motor IP 54)


The values listed below are approximate values, they refer to a screw compressor unit including oil fill :

NT PRI

020

SPRINT 005/006/007 SPRINT 010/011/012 SPRINT 015/016/017 SPRINT 020/021/022 SPRINT 025/026/027 SPRINT 030/031/032 SPRINT 040/041/042 SPRINT 045/046/047

approx. 210 kg approx. 215 kg approx. 245 kg approx. 265 kg approx. 400 kg approx. 415 kg approx. 445 kg approx. 465 kg

5.2 Installation

Fig. 6
A A A

Danger.
The screw compressor unit must be lifted using a suitable fork lift truck, which complies with the local safety regulations. Before lifting, all loose or slewable parts of the machine have to be firmly secured. It is strictly prohibited to work or stand in the danger zone of a lifted load. The proper lifting of the load (according to the operating instructions of the load suspension device) has to be ensured.
Fig. 7
B B B

A = 0,5 m B = 0,5 m

Danger.
*

Important
Never lift or lash the compressor via its enclosure. The screw compressor is lifted with the help of a fork lift truck (fig. 6). The separation of the forks and their length must be taken into account for transportation. Only use the identified lifting points. Do not slide the unit when it is standing on the floor.

The foundation weight carrying capacity has to be taken into account. Provide for a solid and plane base. The intakes are to be located so that no hazardous constituent (solvent vapour, etc., but also dusts and other hazardous material) can be sucked in. This applies also to flying sparks. Pipes and/or other parts with a surface temperature higher than 80 C have to be suitably identified and secured against touching.

* *

See also the safety regulations in chapter 3 of the operating instructions.

23

5. Transport and installation

Important
The operator has to provide adequate ventilation for the compressor station. The screw compressor unit has to be levelled. A minimum distance from walls, other machines, etc. should be maintained so that there is sufficient clearance for maintenance and repair work (fig. 7). During operation of the screw compressor unit, heat is generated by the electric motor and the compression process. The screw compressor radiates a part of this heat into the surroundings. Proper ventilation has a considerable effect on the service life and the performance of a compressor.

24

6. Preparations for commissioning

6.1 Cooling air volume/minimum crosssections

Important
The stated minimum cross-section refers to a maximum duct length of 5 m and a maximum of one bend. In case of differing values (over 5 m, more than one bend, filter cartridges, screens, etc.) please contact your technical adviser.

Mannesmann Demag screw compressors are rated for ambient temperatures and cooling air temperatures of +1 C to +40 C. In the case of temperatures other than the above limiting values, please consult your technical adviser. 1

6.2 Compressed air connection


The screw compressor is completely assembled in the factory. The compressed air mains is connected to the tapping flange of the screw compressor.

Fig. 8 1 2 Cooling air intake Cooling air outlet 2

Note
In order to ensure a good heat dissipation, auxiliary fans should be rated to process approximately 15 to 20 % more air volume than the total cooling air volume required by the compressors installed in the compressed air station.

1 Fig. 10

Note
Fig. 9 The cooling air volume required by these screw compressors is as follows : SPRINT 005/006/007 SPRINT 010/011/012 SPRINT 015/016/017 SPRINT 020/021/022 SPRINT 025/026/027 SPRINT 030/031/032 SPRINT 040/041/042 SPRINT 045/046/047 approx. 15 m3/min approx. 22 m3/min approx. 36 m3/min approx. 36 m3/min approx. 56 m3min approx. 56 m3/min approx. 75 m3/min approx. 84 m3/min

After-coolers, separators, collecting reservoirs and the compressed air lines must be equipped with drain facilities at their lowest points to drain collected liquids. These facilities have to be fitted to allow the observance of the draining of such liquids. Hand-operated drain facilities have to be actuated in accordance with the operating instructions. Automatic drain facilities have to be checked for proper function at regular intervals. When draining condensates into a collecting line, which also collects the condensate from other machines, make sure that the collecting line is free from counterpressure. Therefore, measures have to be taken to ensure that counterpressure cannot build up. Condensate may contain oil ! When draining condensate, observe the corresponding regulations for waste water disposal.

Under unfavourable local conditions, we recommend the installation of venting ducts. However, the velocity of the cooling air should not exceed 5 m/s. We recommend a minimum cross-section of approx. 0.1 m 2.

25

6. Preparations for commissioning

6.3 Electrical connection


Recommended supply line cross-sections and fuses. Laying of supply line according to VDE 0100, part 523 - group 2, mulit-wire cables.

Sprint 380 V/50 Hz

Installed nominal motor power [kW]

Fuse protection (slow-blow fuse) [A] 20 20 35 35 35 50 50 63 Fuse protection (slow-blow fuse) [A] 20 20 25 35 35 50 50 63

Line crosssection at 30 C [mm] 2.5 2.5 6 6 6 10 10 16 Line crosssection at 30 C [mm] 2.5 2.5 4 6 6 10 10 16

005/006/007 010/011/012 015/016/017 020/021/022 025/026/027 030/031/032 040/041/042 045/046/047 Sprint 400/415 V/50 Hz

5.5 7.5 11 15 15 18.5 22 30 Installed nominal motor power [kW] 5.5 7.5 11 15 15 18.5 22 30

005/006/007 010/011/012 015/016/017 020/021/022 025/026/027 030/031/032 040/041/042 045/046/047 (Max. line length 50 m)

Danger.
A main switch and main fuse have to be connected by the customer in the incoming line of the screw compressor unit and have to be fitted away from the screw compressor (unless factory-mounted as special accessories). The electrical connection and the protective measures have to be carried out by an authorized electrician in line with VDE regulations (and the national stipulations in your country) and additional rules of the respective electrical power supplier.
The screw compressor unit is completely factory-wired and complies with all VDE 0100/EN 60204 (VDE 0113) standards. The electrical connection is to be made by an authorized electrician in accordance with VDE regulations and/or the regulations in your country and additional rules of the respective electrical power supplier.

The customer has to fit a main switch in the incoming line of the unit. Maximum length of line 50 m at a maximum temperature of 30 C. The supply line cross-sections given (to VDE 0100, group 2) have to be considered as recommended values. In the case of differing conditions (length, temperature, groupings), the cross-sections have to be determined in line with DIN VDE 0298, part 4. In the case of a voltage drop, a safety circuit prevents the screw compressor from starting automatically when the voltage is again applied. The unit can only be restarted after acknowledgement of the fault "power failure" by pressing the OFF-key.

26

6. Preparations for commissioning

Check the supply voltage connection

Serie

The adjustment of the control-power transformer is at an optimum level, if the voltage measured for control power transformers with 0 and 220 V terminals is 220 V to 240 V and for control power transfomers with 0 and 230 V terminals is 240 to 250 V.

Check direction of rotation


435V 415V 400V 380V 360V

Option

Fig. 11

Danger.
For this, the unit must be off circuit.

Important
Fig. 12 The terminal of the control at the control-power transformer has been connected to 400 V (for an external conductor voltage of 400 V) in the factory. For other external voltages (380 V or 415 V) the terminal connection at the control-power transformer has to be changed (see circuit diagram) ! Voltages which are too low or too high can cause damage to the machine. The adjustment of the control-power transformer therefore forms an integral part of both commissioning and regular inspection, since the mains voltage may have changed in the meantime. Check that the control-power transformer in the switch cabinet of the compressor unit is wired according to the available and measured voltage of the electric network. * The rated voltage has been factory-connected to the 400 V terminal of the control-power transformer. If the measured voltage of the network differs from the rated voltage of 400 V, change the terminal connection at the control-power transformer accordingly (fig. 11).

Check the direction of rotation as follows : * When checking the direction of rotation, switch off the screw compressor only by means of the emergency shutdown switch. During the first start-up, the direction of rotation must be checked (see arrow) ! The screw compressor unit must not run longer than a max. 2 seconds in the wrong direction of rotation. If required, reverse the terminal connections.

* * *

Important
Operation of the unit in the wrong direction of rotation for more than 2 seconds will result in considerable damage to the compressor !

If this is not the case : * * * * De-energize the system ! Change the terminal connections of the controlpower transformer. Start the machine. Measure the output voltage at the 0 and 220 or 0 and 230 V terminals (depending on the controlpower transformer, see terminal identification) during load operation using a voltmeter.

27

6. Preparations for commissioning

6.4 Oil level check

Check oil level * The oil level is checked with the help of the oil dip stick at the pressure reservoir (fig. 13 + 14) after every stop and at regular intervals. The oil should have settled and the air entrapped should have been dispersed. This procedure may take up to one hour (depending on the conditions). Unscrew the oil dip stick Pull the oil dip stick out Check the oil level; the level must be above the minimum marking on the oil dip stick. If required, top up oil. See also chapter 9 "Maintenance.

Danger.
Only check the oil level when the screw compressor unit is out of operation and depressurized !

The pressure reservoir can be under pressure and the oil hot. Warning : Danger of scalding ! Do not spill oil !
*

Check for leakage !


* *

6.5 Sound pressure level


Sound pressure level measured to DIN 45 635 under full load at a distance of 1 m dB(A): dB(A) Fig. 13 SPRINT 005/006/007 SPRINT 010/011/012 SPRINT 015/016/017 SPRINT 020/021/022 SPRINT 025/026/027 SPRINT 030/031/032 SPRINT 040/041/042 SPRINT 045/046/047 Subject to technical revision. 68 72 72 72 67 68 72 73

Fig. 14

Important
Do not mix oils of different specifications.

28

7. Commissioning

7.1 First commissioning

Danger.
Make sure before commissioning that nobody is in the danger zone of the motor/screw compressor. Only operate the screw compressor with closed access panels. The safety valve can be hot as a result of preceding operation. A functional check must only be carried out at operating pressure. Be careful with escaping air (danger of burning and scalding).

* * *

Before each commissioning, check the safety valve (fig. 15) for function by turning the knurled cap at the safety valve (at operating pressure). When switching the power supply on, all of the LEDs and all segments of the LCD displays will light up for a display test. For testing purposes, all LEDs and segments on the operating panel light up. Press the OFF-key for unlocking. Press the ON-key, the ON-key lights up >>green<< in order to show that the screw compressor unit is in the automatic operating mode.

Important 7.2 Routine commissioning


Although every Mannesmann Demag screw compressor has been subjected to a test run at the factory and has again been thoroughly inspected before shipment, damage during shipment cannot be excluded. For this reason, every screw compressor should be checked once again for damage before being commissioned. In addition, it should be observed during the first operating hours. The screw compressor unit is completely factory-assembled. It can be directly connected to the compressed air mains by means of a flexible connection. If the screw compressor is newly connected to a power supply, check the direction of rotation of the drive motor ! With a wrong direction of rotation, shut down the unit immediately by actuating the emergency shutdown, otherwise the compressor might suffer serious damage. The access panels may temporarily be opened for checking the direction of rotation (wear ear protectors). Moreover, the following points must be taken into account : * Fasteners (if any) used for securing the unit during transportation have to be removed prior to commissioning. Before first commissioning, panels and doors should be realigned, if required. Check and, if necessary, correct the pre-set values at the Kondensomat (option). Re-tighten all connecting terminals of the electrical control before commissioning. Check the oil levels in the pressure reservoir before each commissioning. Open isolator valves between the screw compressor, reservoir and pipe, Operate main switch.

Fig. 15

Danger.
Make sure before commissioning that nobody is in the danger zone of the motor/screw compressor. After completion of work : Verify that all safety devices have been refitted and that all tools have been removed. Only operate the screw compressor unit with closed access panels. Before each commissioning, check the safety valve (fig. 15) for function by turning the knurled cap at the safety valve (at operating pressure). The safety valve can be hot as a result of preceding operation. A functional check must only be carried out at operating pressure. Be careful with escaping air (danger of burning and scalding).

* * * * * *

29

7. Commissioning

Note
The condensate separator (option) and the condensate drain (option) have to be installed by the customer. Before first commissioning or when re-commissioning after maintenance of the water-cooled units, the air cooler must be bled via the bleed screw.
Before each commissioning of the screw compressor follow the steps below : * * * * * * * Check the oil levels in the pressure reservoir. Open the isolator valves between the screw compressor, reservoir and pipework. Actuate main switch. Check the safety valve at operating pressure. For testing purposes, all LEDs and all segments on the operating panel light up. Press the OFF-key for unlocking. Press the ON-key, the ON-key lights up >>green<< in order to acknowledge that the screw compressor unit is in the automatic operating mode.

7.4 Operating modes Automatic operation


The generation of compressed air is stopped when the set maximum operating pressure has been achieved, and the electric motor stops after a corresponding coasting time (dependent upon the electrical network). The generation of compressed air commences and the electric motor cuts in, when the operating pressure has decreased to the set minimum value.

7.5 Setting of the operating pressure

Start-up protection of the electric motor


The screw compressor unit does not start up, if the system pressure is higher than 0.8 bar. Fig. 16

Temperature start-up protection


The screw compressor unit does not start up, if the ambient temperature is lower than +1 C.

Danger.
The operating pressure must be set by a specialist only. The operating pressure must not be set higher.

7.3 Commissioning after malfunction Important


Do not switch the screw compressor on repeatedly without having rectified the malfunction, since this may cause considerable damage to the machine. Re-start after an automatic shutdown due to malfunction: * * * * * Operate emergency shutdown Rectify malfunction Unlock emergency shutdown Press OFF/acknowledgement key The screw compressor unit can only be restarted when the OFF/acknowledgement key has been pressed. * Start the screw compressor unit by pressing the ON key I.

Important
The operating pressure is set at the pressure monitor as follows : SPRINT 005/010/015/020/025/030/040/045 to 8.0 bar SPRINT 006/011/016/021/026/031/041/046 to 10.0 bar SPRINT 007/012/017/022/027/032/042/047 to 13.0 bar

The settings of the switching points (pressure range) have to be checked by means of a pressure gauge. It is possible to reduce the operating pressure to a minimum of 5 bar. The pressure difference (p) must not be smaller than 0.5 bar. Generally, it should be 10 % of the operating pressure. The admissible maximum number of motor cycles is controlled by the DELCOS electronics.

30

7. Commissioning

7.6 Monitoring
The operating pressure and the compressor temperature can be read from the operating panel in the pressure display (bar) and temperature display (C). Compressors with oil-lubricated pressure chambers are to be operated in a manner that avoids exceeding of the pre-set final compression temperature. The screw compressor is equipped with an automatic operation monitoring system, which shuts the unit down in the case of the following malfunctions. 1 - Excessive temperature of the screw compressor 2 - Excessive temperature of the electric motor

Important
Warning : Electric voltage ! Encoders for automatic operation monitoring must not be bridged ! The screw compressor unit must not be operated with bridged encoders !

31

8. DELCOS-S Electronics

8.1 Operating elements


6 6.1-6.4

bar

I
C

0
Drucklufttechnik h

3
Fig. 17

7 7.1-7.4

1 2

Emergency shutdown (self-locking) Light emitting diode (LED) = Excessive motor temperature - the screw compressor changes over to standstill mode and locks. Light emitting diode (LED) = Temperature of compressor T < 1 C or T > 100 C. The screw compressor changes over to standstill mode and locks. ON-key * Permanent green = Screw compressor unit is running * Flashes green = Motor stopped during automatic operation

OFF/acknowledgement key and for unlocking after malfunction Display = Operating pressure Display = Compression temperature Operating hours counter - total hours

6 7

Note
If all of the light emitting diodes (LEDs) are alight, it indicates that a power failure has occurred. This is also the case when the emergency shutdown has been pressed and then unlocked; this also functions as a display test. Press the OFF/acknowledgement key (5) to reset.

Danger
At this stage, the screw compressor unit can restart at any time.

Danger.
Make sure before commissioning that nobody is in the danger zone of the motor/screw compressor. After completion of work : Verify that all safety devices have been refitted and that all tools have been removed. Only operate the screw compressor with closed access panels.

32

8. DELCOS-S Electronics

8.2 LED "operating pressure" (bar)

8.3 LED "temperature" (C)

6.1/6.2

6.3

7.1

7.2

12.1

12.2

6.5 6.4
Fig. 18 6.1 6.2 Permanent display of operating pressure When the max. operating pressure is exceeded by approx. 10 %, the permanent display flashes : Fig. 19 7.1

7.3

Permanent display of the compression temperature With a temperature <1 C or >100 C, the screw compressor unit stops and locks. The temperature display flashes as long as T <1 C or >100 C. This check point flashes when the screw compressor unit slows down, because the soft-stop time was started at the soft-stop relay or the OFFkey was pressed. The check point goes out when the set soft-stop time has been reached. Then, the screw compressor unit stops and the ON-key flashes >>green<<.

7.2

SPRINT 005/010/015/020/025/030/040/045 > 8.3 ba SPRINT 006/011/016/021/026/031/041/046 > 11.0 bar SPRINT 007/012/017/022/027/032/042/047 > 14.3 bar 7.3 6.3 When the max. operating pressure is exceeded to a value of :

SPRINT 005/010/015/020/025/030/040/045 9.5 bar SPRINT 006/011/016/021/026/031/041/046 11.5 bar SPRINT 007/012/017/022/027/032/042/047 14.5 bar the screw compressor unit changes over to standstill mode and locks. The pressure display and >>E<< = Error flash alternatingly. 6.4 The lighting of this check point follows the shortcircuit of a solenoid valve, i.e. the screw compressor unit goes into the standstill mode. With DELCOS-SM electronics (option), checking point 6.4 has an additional function. Decimal point for the pressure display.

Note
The timer is factory-set and may only be adjusted by authorized personnel.
If your screw compressor unit is fitted with a DELCOSSM PROG, please also observe the operating instructions BA 436 for DELCOS-SM PROG.

8.4 DELCOS-SM
DELCOS-SM electronics (option) If your screw compressor unit is equipped with a DELCOS-SM control, the following items are indicated by means of LEDs on the operating panel: 1 p* fine separator 2 p* oil filter 3 p* air filter 4 Collective fault (when this LED lights up, check in the switch cabinet and determine the fault utilizing the lit LED as a basis). If LED 4 lights up alone, another warning (LED) must be lit. If LED 4 lights up in conjunction with check point 6.4, another fault message (LED) must be present. The lighting up of checking point 6.4 alone indicates a short-circuit of a solenoid valve. *p = differential pressure

6.5

33

9. Maintenance

9.1 Maintenance recommendations

9.3 Maintenance schedule

Note
The screw compressor unit can only operate to your complete satisfaction, when the maintenance work is carefully carried out at the specified intervals.
In order to facilitate this task, the scope of supply of the screw compressor unit comprises the "Maintenance and inspection manual for Mannesmann Demag compressors", in which you can list your performed maintenance work at the specified intervals. The operating hours stated herein are recommended maintenance intervals for average operating conditions. Depending on the intake conditions, the operating times may differ. You can also have this maintenance work performed by our trained technicians. Please ask your technical adviser for a maintenance contract. For compressor lubrication, the employer has to provide oils which are, with regard to their composition, viscosity, inflammation point and resistance to aging, suitable to the relevant operating conditions. Do not use other oils.

Danger.
When carrying out control, adjusting and maintenance work, be careful with hot surfaces of machine parts. Checking and maintenance work may only be carried out when : * Press the OFF-key on the control panel and wait until the screw compressor unit has come to rest; the screw compressor unit is depressurized, the pressure display does no longer indicate pressures < 0.3 bar. Shortly after switching the screw compressor off, the system can contain a low residual pressure. The screw compressor unit must therefore be unloaded prior to any maintenance work by slowly opening the plug (oil fill hole) with integral venting bore. The customer-installed main switch is set to "0" (OFF); Warning : Electrical voltage: Only work on the screw compressor unit when it is disconnected.

* *

9.2 Maintenance electric motor


The maintenance of the electric motor is to be performed in line with the motor operating instructions.

34

9. Maintenance

Maintenance items
W 1 Oil change (mineral oils)1) in a normal industrial environment (when in doubt with regard to the oil change intervals - 3000 OH, have your oil supplier carry out an oil analysis) W 2 Replacement of the oil filter cartridge in a normal industrial environment (recommended in connection with an oil change, or after the response of the oil filter p monitor, if installed) W 3 Replacement of the oil fine separator cartridge in a normal industrial environment (or replacement after the response of the filter p monitor, if installed) W 4 Replacement/check of air filter cartridge in a normal industrial environment (or replacement after the response of a filter p monitor, if installed) W 5 Safety valve W 6 V-belt - only visual check W 7 Connecting terminals in the switch cabinet of the electric motor W 8 Fittings W 9 General maintenance/cleaning In the case of a very dirty atmosphere, the cleaning intervals have to be shortened as required.

1)

Oil changes when the Mannesmann Demag special oil "blue energy" (option) is used. 1st change after 3000 h, then every 10000 h, however, after three years at the latest.

Maintenance plan OH W W 11 W2 W3 W4 W5 W6 W7 W8 W9 During 100 commissioning 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

These maintenance intervals have to be adhered to !

35

9. Maintenance

9.4 Oil change

Note
When changing the oil, the waste oil is to be drained completely, if possible, since used oil reduces the service life of the new oil fill considerably. Lubricants of different types should not be mixed. When changing over to a new oil type, the oil in the oil circuit must be drained completely.
For the oil change intervals, see the maintenance schedule. When changing the oil, proceed as follows : * * Open the oil filling hole: In order to do this, unscrew the oil dip stick and pull it out Open the oil drain (fig. 20) of the pressure reservoir and the oil cooler Drain the oil at operating temperature Close the oil drain Fill in oil: SPRINT 005 - 022 approx. 5 L SPRINT 025 - 047 approx. 7 L use high-quality oils only, see chapter 9.13 Close the oil filling hole with the oil dip stick: For this, screw the oil dip stick in, together with a new or annealed copper washer, and tighten it Let the screw compressor unit run for approx. 2 minutes and check for leakage Switch the screw compressor unit off Check oil level : For this, the oil should have settled, i.e. the entrapped air should have been dispersed The oil level must be above the minimum marking of the oil dip stick If required, top up oil.

Fig. 20

Danger.
The oil must only be changed, when the screw compressor is out of operation and depressurized ! Be careful when draining hot oil : Danger of scalding !

* * *

Important
Remove oil residues and other deposits from unit parts and from the coolers of compressors, which are exposed to hot compressed air, according to the operating instructions.

* *

* *

Note
Collect the waste oil, let not seep away into the soil ! Disposal in accordance with the regulations ! Do not spill oil ! Check for leakage ! With these compressors, the oil change intervals strongly depend on the degree of contamination of the circulating oil. It must therefore be taken care that no oildeteriorating matter (dusts, vapours, gases) are transported through the air intake filter into the oil circuit of the compressor unit. Also a high content of humidity in the intake air and the formation of condensate within the machine affect the service life of the lubricant oil so that a reduction in the oil change intervals may become necessary. The specified oil change intervals refer to an intake air from a normal environment without a high content of foreign matter (dusts, vapours, gases). If, under favourable conditions, it is intended that the oil service life be extended, oil samples have to be examined, and the extension of the operating time is to be determined on the basis of these analysis results.

Changing intervals for lubricants


The operating conditions (e.g. coolant temperatures), the operating modes and the quality of the intake air (e.g. content of dust, content of gaseous foreign matter such as SO2, solvent vapours, etc.) have a strong influence on the oil change intervals. We therefore recommend to have your mineral oil supplier work out oil analyses in the starting time. This is required in any case, if the specified oil change intervals are to be extended.

36

9. Maintenance

9.5 Change of the oil filter cartridge

Make sure that the screw compressor unit is depressurized. Change the oil filter cartridge as follows : * Unscrew the oil filter cartridge using an appropriate tool * Dispose of the oil filter cartridge according to the regulations * Oil the gasket of the new oil filter cartridge slightly * Screw on the new oil filter cartridge and tighten manually (take notice of the instructions on the oil filter cartridge) * Check for leakage * Check oil level * If required, top up oil.

Changing intervals for oil filter cartridges


Fig. 21 The operating conditions (e.g. coolant temperatures), the operating modes and the quality of the intake air (e.g. content of dust, content of gaseous foreign matter such as SO2, solvent vapours, etc.) have a strong influence on the service life of the filters.

9.6 Change of the oil fine separator cartridge

Fig. 22

Danger.
Only replace the oil filter cartridge, when the screw compressor unit is out of operation and depressurized ! Be careful with hot oil : Danger of scalding ! Do not spill oil !

Fig. 23

Note
Dispose of the oil filter cartridge in line with the regulations - special waste - ! Check for leakage !
For the changing intervals, see the maintenance schedule. If the oil filter cartridge is monitored (option), a high differential pressure is indicated at the operating panel. If the corresponding LED lights up, change the oil filter cartridge.

Danger.
The pressure reservoir is under pressure ! Only work on the screw compressor unit, when it is out of operation and depressurized ! Be careful with hot oil : Danger of scalding ! Do not spill oil !

Note
Dispose of the fine separator cartridge in line with the regulations - special waste - ! Check for leakage !

37

9. Maintenance

For the changing intervals, see the maintenance schedule. If the oil fine separator cartridge is monitored (option), a high differential pressure is indicated at the operating panel. If the corresponding LED lights up, change the oil fine separator cartridge. Make sure that the screw compressor unit is depressurized. Change the oil fine separator cartridge as follows : * * * * Unscrew the oil fine separator cartridge using an appropriate tool Dispose of the oil fine separator cartridge according to the regulations Oil the gasket of the new oil fine separator cartridge slightly Screw on the new oil filter cartridge and tighten manually (take notice of the instructions on the fine separator cartridge) Check for leakage Check oil level If required, top up oil

Danger.
Only perform checks and carry out work on the screw compressor when the unit is out of operation and depressurized !

Important
Never operate the screw compressor unit without air filter (even a short operating time without this filter can result in considerable damage to the machine) ! If the air filter cartridge is monitored (option), a high differential pressure is indicated on the operating panel. When the corresponding LED lights up, the air filter cartridge is to be replaced. Check the air filter for accumulated dust at least once a week or, if required, daily. During maintenance work, take care that no dirt enters the clean air side of the air filter.

* * *

Changing intervals for oil fine separators


The operating conditions (e.g. coolant temperatures), the operating modes and the quality of the intake air (e.g. content of dust, content of gaseous foreign matter such as SO2, solvent vapours, etc.) have a strong influence on the service life of the filters.

Maintenance of the air filter


Maintenance of the air filter is carried out as follows: * * * Loosen the wing nut on the air filter cover, remove the cover, remove the clogged air filter cartridge Important : Never clean the air filter cartridge with benzin or hot fluids. insert the new air filter cartridge until it sits firmly on the bottom of the housing, attach and fasten the cover by means of the wing nut.

9.7 Air filter change/check

* *

Changing intervals for filter and separator cartridges


The operating conditions (e.g. coolant temperatures), the operating modes and the quality of the intake air (e.g. content of dust, content of gaseous foreign matter such as SO2, solvent vapours, etc.) have a strong influence on the service life of filters (air filters, oil filters, fine separators).

Fig. 24

38

9. Maintenance

9.8 Safety valve

9.9 V-belts - automatic tensioning system

Danger.
Only perform checks and carry out work when the screw compressor unit is out of operation and depressurized ! Any safety equipment which had to be removed for the replacement of the V-belt set must be remounted after completion of this work.

Important
The replacement of a single V-belt is not permitted, always replace a complete V-belt set. During the entire service life of the V-belt set, no readjustment of the automatic V-belt tensioning system will be necessary.

Fig. 25

Danger.
Never operate a screw compressor unit with a defective safety valve ! Before each commissioning, check the safety valve for function by turning the knurled cap at the safety valve at operating pressure. If the safety valve does not function properly, it must be immediately replaced by a new safety valve with the corresponding pressure rating. The safety valve can be hot as a result of previous operation ! Escaping air can be hot and contain oil (danger of burning/scalding) !
Fig. 26 The V-belt set is changed as follows: * * Remove the V-belt set; for this, the automatic belt tensioner must be relieved. Put on the new V-belt set; the correct V-belt tensioning rate is provided by the automatic V-belt tensioner.

When changing the V-belt set, take care that the pulleys are aligned.

39

9. Maintenance

9.10 Connecting terminals in the switch cabinet

9.14 Lubricant recommendations for stationary compressors Lubricant recommendation


Please note that proper lubrication will considerably increase the service life of your compressor unit. According to the Accident Prevention Regulations for Compressors (VGB 16), lubricating oils are to be used, the properties of which correspond to the intended operating conditions. When in doubt, please contact the manufacturer or your oil supplier. Mixing of different lubricant oils should be avoided. This means also that, when changing over to another type of oil, the old oil is to be drained completely from the oil circuit. Unless specified otherwise, all lubricant oils should comply with ISO VG 32 DIN 51519, July 1976, with 2835 mm/s (cSt)/40 C (with regard to viscosity comparable to SAE 10 W to DIN 51511, February 1973) or at permanent ambient temperatures above +15 C of the viscosity class to ISO VG 46, DIN 51519, July 1976, with 41-50 mm/s (cSt)/40 C (with regard to viscosity comparable to SAE 15 W to DIN 51511, February 1973). In particular, the following is to be used : a) Lubricant oils VCL to DIN 51506, August 1982 b) Special oils for screw compressors with oil injection cooling c) In a dirty industrial atmosphere, motor oils to MIL-L-2104 C d) Turbine oils L-TD DIN 51515 with an FZG value > 10 e) Mannesmann Demag "blue energy" Before using synthetic lubricants, consult the manufacturer.

Danger.
In the case of electric voltage : * * Actuate OFF-key at the operating panel Set the customer-fitted main power switch to "0" (OFF)

The connecting terminals in the switch cabinet have to be checked and, if required, retightened during first commissioning and later on in line with the maintenance schedule.

9.11 Fittings
The fittings of the air and oil circuits have to be checked and, if required, retightened according to the maintenance schedule.

9.12 General maintenance and cleaning Important


Remove oil residues and other deposits from unit parts and from the coolers of compressors, which are exposed to hot compressed air, according to the operating instructions. Blow off the screw compressor unit with compressed air at the specified intervals (never aim compressed air at persons) paying particular attention to : * * * * * Regulating elements Fittings Compressor block Cooler Electric motor

40

10. Trouble-shooting

Malfunction Unit cannot be started

Possible cause 1. No operating or control voltage 2. Malfunction not acknowledged 3. Pressure reservoir not depressurized 4. Electric motor defective 5. Compressor defective 6. Ambient temperature less than +1 C

Remedy 1. Check fuses, main switch and supply line 2. Acknowledge fault message 3. Wait until depressurized, the reservoir pressure must be < 0.8 bar for a start 4. Check connections, winding, etc. 5. Turn the compressor manually; if required, replace 6. Make sure that the ambient temperature is not less than +1 C; install an auxiliary heater, if required. 7. Check sensors, connections and lines

7. Display shows >>E<< in the pressure or the temperature display Unit stops during the start-up phase 1. The intake regulator closes only partly

1. Repair or, if required, replace the intake regulator; check solenoid valve - 20 - and throttle - 13 2. Determine and eliminate cause; replace defective fuses 3. Check and re-tighten 4. Check the pressure holding valve and the opening function of the intake regulator 5. Select the type of oil according to the ambient conditions or install an auxiliary heater 6. Check sensors, connections and lines 7. Avoid frequent manual on and off-switching, let electric motor cool down 8. Correct timer

2. Short-circuit in the unit 3. Connecting terminals in the switch cabinet are loose 4. No or insufficient pressure builds up in the pressure reservoir during the phase 5. Oil too viscous

6. >>E<< appears on the display 7. Maximum motor switching cycles exceeded due to too frequent manual on and off-switching 8. Timer for Y/-circuit set too short Unit does not reach the end pressure

1. Pressure monitoring device set too low 1. Check, re-set 2. Intake regulator opens only partly 3. Excessive air consumption 4. V-belt slips 5. Oil fine separator clogged 6. Air filter clogged 7. Heavy leakage in the compressor system 2. Repair or, if necessary, replace intake regulator; check throttle -13 3. Reduce consumption or cut in a further compressor 4. Replace the V-belt set and clean the face of the pulleys 5. Replace oil fine separator 6. Replace air filter cartridge 7. Check unit

41

10. Trouble-shooting

Malfunction Unit switches off

Possible cause 1. Ambient temperature too high 2. Ventilator defective 3. See pressure or temperature displays

Remedy 1. Ventilate compressor room 2. Check el. motor and protective motor switch 3. Check sensors, connections and lines

4. Cross-section of the electric supply lines 4. Measure power requirement, if necessary, too small replace lines 5. Power requirement too high 6. Oil level too low 7. Oil injection pressure too low 8. Excessive oil temperature 9. Oil foam in the system 10. Maximum motor switching cycles exceeded due to too frequent manual on and off-switching 5. Oil fine separator or air filter cartridge clogged; replace, if necessary 6. Top up oil in the pressure reservoir 7. Replace oil filter cartridge, clean oil system 8. Check oil cooler and ventilator 9. Check oil, if requried switch over to another type of oil (drain completely) 10. Avoid manual on and off-switching, let electric motor cool down

Excessive idling pressure 1. Intake regulator does not close correctly 1. Check intake regulator - 2 -; check and, if required, clean throttle - 13 2. System not unloaded Insufficient idling pressure 1. By-pass drilling in the intake regulator clogged 2. Control line leaking Oil in the compressed air 1. Oil fine separator defective 2. Oil foams 3. Oil level too high 4. Blow-off time insufficient 5. Check valve defective 2. Check solenoid valve (20) and lines 1. Check intake regulator - 2 -; check by-pass drilling 2. Check control line 1. Replace 2. Change oil, blow-off time too short 3. Drain off oil 4. Insert a smaller blow-off nozzle 4. Replace check valve

42

10. Trouble-shooting

Malfunction Oil in the air filter

Possible cause 1. Packing spool in the intake regulator defective

Remedy 1. Check sliding fit and sealing surface and replace, if necessary

2. Intake regulator does not close correctly 2. Check intake regulator and solenoid valve - 20 -; check and, if required, clean throttle - 13 3. Blow-off time too short 4. Check valve defective Safety valve opens 1. Safety valve defective 3. Extend time (nozzle) 4. Remove check valve 1. Replace

Never operate the screw compressor with defective safety valve ! 2. Oil fine separator clogged 3. Intake regulator closes too slowly 2. Replace 3. Check intake regulator and solenoid valve - 20 -; check and, if required, clean throttle - 13 4. Replace 5. Replace 6. Replace 1. Replace 2. Replace

4. Pressure monitoring device defective 5. Electronics defective 6. Solenoid valve defective System is not bled after stopping 1. Solenoid valve defective 2. Check valve to compressed air mains defective

43

Service
Deutschland Mannesmann Demag Drucklufttechnik Zentral-Ersatzteildienst Argenthaler Strae 11 D-55469 Simmern/Hunsrck Postfach 169 D-55461 Simmern/Hunsrck Telefon 0 6761/83 20, Telefax 0 6761/12 74 6 Telex 42 64 22 Niederlassung Essen Hilgerstrae 8 D-45141 Essen Postfach 100965 D-45009 Essen Telefon 0 201/31 10 33 Telefax 0 201/31 36 70 Niederlassung Frankfurt Borsigallee 20 D-60388 Frankfurt Telefon 0 69/42 09 98 39 Telefax 0 69/41 53 80 Niederlassung Stuttgart Leobener Strae 63 D-70469 Stuttgart Postfach 300760 D-70447 Stuttgart Telefon 0 711/98 19 50 Telefax 0 711/98 19 52 0 Niederlassung Leipzig Holzhuser Strae 122 D-04299 Leipzig Telefon 0 341/86 77-222 bis 227 Telefax 0 341/86 77-250 sterreich Mannesmann Demag Frdertechnik GmbH Bereich Drucklufttechnik Gniglerstrae 57 A-5021 Salzburg Telefon 06 62/8 89 06-0 Telefax 06 62/8 89 06-118 Service-Hotline 06 60/72 22 Schweiz Fehr Demag AG Division MD Drucklufttechnik Bahnhofstrae 3 CH-8305 Dietlikon Telefon 01/8 35 11 11 Telefax 01/8 35 14 40 Italien Mannesmann Demag S.p.A. Division Aria Compressa Via Archimede, 45/47 I-20041 Agrate Brianza Mi Telefon 0 39/65 53.1 Telefax 0 39/6 05 64 58 Roma Grande Raccordo Anulare km 29, Nr. 3345 I-00131 Roma Telefon 06/4 13 13 89 Telefax 06/4 19 07 75 England Mannesmann Demag Ltd. Compressed Air Division Featherstone Road Wolverton Mill GB-Milton Keynes MK12 5QN Phone 019 08/22 59 96 Fax 019 08/22 59 84 Sdafrika Mannesmann Demag (Pty.) Ltd. P.O. Box 10394 SA-Johannesburg 2000 Sdafrika Phone 011/4 03 52 00 Telefax 011/4 03 14 37 Telex 4-2 24 33 Frankreich Mannesmann Demag Division Air Comprim Parc Gustave Eiffel 6 Avenue Gutenberg BP 9 - Bussy Saint-Georges F-77607 MARNE-LA-VALLEE Cedex 03 Tl. 16 (1) 64 76 45 00 Fax 16 (1) 64 76 46 99 Tlex (1) 69 47 56 F Centres de service et Bureaux en France Bussy Saint-Georges Parc Gustave Eiffel 6 Avenue Gutenberg BP 9 - Bussy Saint-Georges F-77607 MARNE-LA-VALLEE Cedex 03 Tl. 16 (1) 64 76 46 12 Fax 16 (1) 64 76 46 89 Tlex (1) 69 47 56 F Chlons sur Marne 5 rue Ampre - BP 539 F-51012 Chlons-sur-Marne Cedex Tl. 26 64 51 62 Fax 26 65 02 28 Tlex 83 05 25 Lille S.A.R.L. de LEpinoy, Btiment 3 Route de Vendeville F-59175 Templemars Tl. 20 62 9717 Fax 20 96 37 90 Lyon 13 route du Prollier F-69570 Dardilly Tel. 78 66 42 00 Fax 78 35 38 64 Metz 35 rue des Garennes F-57157 Marly Tl. 87 38 09 88 Fax 87 38 09 87 Nantes 3 bis Quai Hoche F-44200 Nantes Tl. 40 20 50 80 Fax 40 35 31 54 Toulouse 15 Chemin des Cujalas F-31120 Roques-sur-Garonne Tel. 61 72 04 40 Fax 61 72 48 28 Colmar 5 rue Emile Schwoerer BP 1201 F-68012 Colmar Cedex Tl. 89 41 25 52 Fax 89 41 58 65

Technische nderungen vorbehalten

Subject to technical revision

Sous rserves de modifications techniques

Mannesmann Demag Drucklufttechnik Argenthaler Strae 11 D-55469 Simmern/Hunsrck Postfach 169 D-55461 Simmern/Hunsrck Telefon 0 6761/83 20, 44 Telefax 0 6761/12 74 6 Telex 42 64 22

Schutzgebhr / Nominal charge / Droit de protection / DM 10.- / $ 5.- / FFr 34.-

100/10.96/4/GB/GS/CT